I've been thinking about this project off and on for a little while. I've come to the conclusion that perhaps the original base revolver I'm planning to use won't work due to the larger scale of the airsoft receiver. I'm thinking a .380 barrel will look too small when looking at the piece as a whole. We all know the original bulldog was .44spl. big size difference there. So in thinking about trying to get the proportions right as well as cutting down on machining cost etc. I'm tempted to buy the longer barrel version of Zoraki viper, also the Zoraki has a pinned barrel which presents another problem when trying to change things around.

I also picked up the machined steel grip frame, trigger guard and, butt plate that (a member here I believe?) sells on ebay. Still need to get grips, sight rod and side covers._________________full tilt boogie baby

Well I bit the bullet so to speak and picked up the longer barrel zoraki yesterday, (the company is having a sale). So, once I have that I'll see where I stand as far as proportions go and then hopefully really dig into this project._________________full tilt boogie baby

As you can see if the rear of the receiver is about where it should be on the revolver we're about 1"-1.5" off the muzzle. Not Ideal, So I'm trying to decide if I'm going to cut down the receiver to match up or lengthen the barrel of the revolver to match

Other update I've contacted a friend of mine who is much more skilled with metal casting than I am (he was a contestant on "Forged in Fire"). He's offered to help me cast some of the custom pieces I'll need. I'll be doing my own sculpting for the pieces (no recasting ). And probably cast them in aluminum._________________full tilt boogie baby

Over the weekend I picked up some super sculpty, and decided to build some custom side covers. First a foremost I am not a very good sculptor. I now have a great deal of respect for those who are. But with my favorite Zatoichi movie in the background I decided to give it a shot. The results are a little rough. I'll have to redo the leftside cover since it deformed during the baking process. These will be used as molds for the metal versions I'll eventually have cast and I think I should be able to refine the shape somewhat to get it closer to what I want._________________full tilt boogie baby

I think what the problem was is that when trying to get the sculpty off the revolver it wouldn't come off cleanly hence the talc. I gave it another go and got slightly better results. We'll see if I can refine them into something I can use, otherwise the next idea is to use aluminum foil in between the gun and the sculpty. Hopefully that will allow me to lift it off cleanly without much prying, and therefore warping on my part._________________full tilt boogie baby

Bravery test! Me and my trusty dremel decided to go to town on the revolver and styer ammo housing. Next I'll set upon the unsuspecting airsoft receiver. I'm still looking for good photos of how the revolver and the receiver fit together. I want to try and do that whole measure once cut twice thing everyone's talking about.

You're not wrong that's for sure. I think I'm going to have to change the barrel on the revolver it just won't look right as it is now, plus I'll be able to get the length I need without further modification to the recevier._________________full tilt boogie baby

I made some progress on the project. I removed the revolver barrel and was slightly surprised to find that while pinned, it was not threaded. I have to assume they did this as a cost saving measure. This will lead to interesting decision for the new barrel I'll be putting on. Do I thread the revolver and the barrel, or stay with the pressed and pinned method?

I also set about cutting the airsoft receiver. I'm not entirely happy with my results, I really wish I had access to a mill for that particular step in the build. I went ahead an purchased another airsoft rifle in the event I come across someone with a mill who is willing to help me out in the future. You may have noticed the receiver doesn't have the tabs at the rear like the steyr does. So figuring out how to mount it to the revolver will undoubtedly lead to more modification. I think I can cut a hole on either side of the receiver then tap for screws into the revolver frame and mount it fairly securely that way.

The outer grip frame continues to vex me. The amber grips I have seem to fit the OffWorld blaster fairly well. Revolver grip frame in the outer, not so much. I'm somewhat leery of cutting the inner grip frame for fear of losing mounting points.

Edited to add pics
Fitment of the receiver to revolver

Rough assembly minus outer grip frame, side covers, and barrel

Sorry for the massive photos. If anyone feels like resizing them, by all means don't hesitate._________________full tilt boogie baby

Last edited by BR12819 on Mon Feb 13, 2017 8:54 pm; edited 2 times in total

It's amazing how much time buying a house and moving across country takes up. I'm finally feeling settled in enough to get back on this project. I managed to find a suitable barrel blank, and am now trying to find a gunsmith willing to work with me on getting the barrel cut down and fitted to the revolver frame. It's not something I feel comfortable doing with a band saw and a drill press.

It's a Steyr part actually what they refer to as a "Trigger Guard" though it contains the ammo housing as well. Mine is from the Model L and the magazine is for 6.5X57

UPDATE:
I dropped the revolver and replacement barrel off at a gunsmith a couple days ago should have it back in about a week will post pics when I have it back in my hands._________________full tilt boogie baby